Melt Shop

Cranes define your melt shop's throughput. Every ladle movement creates dependencies that static calculations can't capture. Our simulation models resolve these dynamics so you invest with confidence.

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Melt shop simulation with crane transport paths

Questions We Help You Answer

  • Can my cranes handle a 15% production increase?
  • Where is the real bottleneck — EAF, LF, VD, or the cranes?
  • Will the new EAF position work with my existing crane setup?
  • How does switching from BOF to EAF affect my logistics?
  • What happens to sequence lengths with the new concept?
  • Do I really need an additional crane?

What We Model

Crane Kinematics

Parallel and sequential movements in all axes, obstacle avoidance, yielding logic for multi-crane bays.

Ladle Lifecycle

From tap to treatment to casting to turnaround — every step with realistic timing per steel grade.

Secondary Metallurgy

LF, VD/VOD, alloy stations with grade-specific treatment times and routing logic.

Tundish Logistics

Preparation, preheating, turnaround, skull removal — the hidden capacity driver.

Auxiliary Transports

Slag pots, big bags, electrode changes, maintenance windows — the work that competes with production.

Production Scheduling

Heat sequences, grade transitions, campaign planning, and full-year simulation with disruptions.

Proven Results

"Saved double-digit million Euros by proving an alternative EAF location achieving the same results."

— ArcelorMittal Eisenhüttenstadt

"Saved 6 million Euros of investment for an additional crane in EAF charging bay."

— ArcelorMittal Long Products Luxembourg

"Revealed a 16% lower productivity than calculated for the new hybrid melt shop concept."

— ArcelorMittal Gent

"Demonstrated the requirement of an additional tilting stand to avoid EAF idle time."

— Dillinger

What's at Stake

Without simulation, you rely on static calculations and engineering judgment. In a melt shop with 3+ cranes and 15+ heats per day, the dynamics are too complex for spreadsheets.

  • Multi-million CAPEX spent on equipment that wasn't needed
  • Production targets missed by 15–25% after commissioning
  • Crane conflicts that nobody predicted in the engineering phase
  • Sequence lengths dropping because the next ladle can't arrive in time

Every one of these was preventable with simulation.

Ready to de-risk your investment? Schedule a Meeting

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Never use averages for crane bottleneck detection in melt shops

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Case Study

15% production increase at AM Long Product Luxembourg

How FESIOS ensured that the cranes at ArcelorMittal Long Product Luxembourg could handle a 15% production increase and the additional workload from a new vacuum degasser.

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